Method for managing and eliminating float threads in knitted garments

Abstract

A method for reducing the occurrence of float threads on the surface of a machine-knitted fabric. Beginning with an initial programmed pattern describing yarn used at each stitch in a knitting pattern, the present method identifies stitches that will create float threads, sorts the identified float threads, giving priority to those float threads that would most limit stretch in a knitted garment, taking into account factors such as float thread length, location in a garment and yarn stretch. Then, in order of the sorted float thread list, the present method assigns additional yarns of the same characteristics as the original yarns to available yarn feeds to minimize the eventual creation of float threads in the knitted fabric. Multiple passes are made through the programmed pattern until no additional floats can be mitigated, or until a predetermined number of passes has been completed.

We claim: 
     
       1. A method for reducing the occurrence of float threads in knitted fabric produced by a computer-controlled knitting machine having multiple yarn feeds controlled by a programmed pattern, in which yarns having specific characteristics in the fabric pattern are assigned to each of a set of yarn feeds with a number of the yarn feeds left unassigned, said method comprising:
 building a list of float threads from the programmed pattern; 
 prioritizing the list of float threads based on at least one predetermined factor, including the length of each float thread; and 
 modifying the programmed pattern based on the prioritized list of float threads to assign at least one unassigned yarn feed to use an existing yarn in the fabric pattern, to thereby reduce float threads. 
 
     
     
       2. The method of  claim 1  further comprising iteratively repeating the following subsequent steps:
 (a) rebuilding the list of float threads from the modified programmed pattern; 
 (b) prioritizing the list of float threads based on predetermined factors, including the length of each float thread; and 
 (c) modifying the programmed pattern based on the prioritized list of float threads to assign at least one unassigned yarn feed to use an existing yarn in the fabric pattern, to thereby reduce float threads. 
 
     
     
       3. The method of  claim 2  further comprising iteratively repeating steps (a) through (c) until no unassigned yarn feeds remain. 
     
     
       4. The method of  claim 2  further comprising iteratively repeating steps (a) through (c) until no additional float threads can be mitigated. 
     
     
       5. The method of  claim 2  wherein one unassigned yarn feed is assigned at step (c) in each iteration. 
     
     
       6. The method of  claim 1  wherein the list of float threads is prioritized based at least in part on the location of the float thread within the knitted fabric. 
     
     
       7. The method of  claim 1  wherein the list of float threads is prioritized based at least in part on the stretch characteristics of the yarn. 
     
     
       8. The method of  claim 1  wherein the list of float threads is prioritized based at least in part on the yarn material. 
     
     
       9. The method of  claim 1  further comprising providing a visualization of the float threads in the knitted fabric produced by the modified programmed pattern. 
     
     
       10. The method of  claim 1  further comprising providing a histogram visualization of the degree of stretch reduced by float threads in the knitted garment produced by the modified programmed pattern. 
     
     
       11. A method for reducing the occurrence of float threads in knitted fabric produced by a computer-controlled knitting machine having multiple yarn feeds controlled by a programmed pattern, in which yarns having specific characteristics in the fabric pattern are assigned to each of a set of yarn feeds with a number of the yarn feeds left unassigned, said method comprising:
 (a) building a list of float threads from the programmed pattern; 
 (b) prioritizing the list of float threads based on at least one predetermined factor, including the length of each float thread; 
 (c) modifying the programmed pattern based on the prioritized list of float threads to assign an unassigned yarn feed to use an existing yarn in the fabric pattern, to thereby reduce float threads; and 
 (d) iteratively repeating steps (a) through (c) with the modified programmed pattern until no additional float threads can be mitigated, or until a predetermined number of iterations has been completed. 
 
     
     
       12. The method of  claim 11  wherein the list of float threads is prioritized based at least in part on the location of the float thread within the knitted fabric. 
     
     
       13. The method of  claim 11  wherein the list of float threads is prioritized based at least in part on the stretch characteristics of the yarn. 
     
     
       14. The method of  claim 11  wherein the list of float threads is prioritized based at least in part on the yarn material. 
     
     
       15. The method of  claim 11  further comprising providing a visualization of the float threads in the knitted fabric produced by the modified programmed pattern.